CLARK FORKLIFT CY 150 165 180 200 (OSM-88-1) SERVICE MANUAL - PDF DOWNLOAD

CLqAK

INDUSTRIAL TRUCK DIVISION

EQUIPMENT

CLqAK

EQUIPMENT

MAINTENANCE MANUAL C L A R K L I F T 150 - 200 CY150, 165, 180s -1-EG'-208 tlv-u 25-542 CY200 -1-G'A-252 thru 14-454

1st

Book No.

Printing

88- J

AUG 75

CLARK EQUIPMENT COMPANY, INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES PUBLICATION DEPARTMENT BATTLE CREEK. MICHIGAN. U.S.A. 49016 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

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Copyrighted Material Intended for CLARK dealers only Do not sell or distribure

INDUSTRIAL TRUCK DIVISION

INSTRUCTIONS ON USE OF MANUAL This Maintenance Manual and Parts Book is published as a service refer• ence guide and includes Parts Information, Trouble Shooting and Specifica• tions where these are applicable.

The Index for the Maintenance Manual is placed at the front of the manual for easy reference. A separate Index for obtaining Parts information is con• veniently located at the beginning of the Parts Section.

The Maintenance Manual is divided into Sections. These being arranged alphabetically according to major assemblies, with the exception of the Op· eration and Lubrication Sections which are placed immediately following the Index.

The Section title and page number appears at the top of the page. Pages are numbered consecutively within each section.

The illustrations appearing, herein, are numbered consecutively within each section and are intended to show typical constructions of the various parts. In some instances, the shapes or details of the parts illustrated may not exactly represent their actual appearance, however, they will serve to show the servicing methods explained and help to identify parts performing the same function.

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Copyrighted Material Intended for CLARK dealers o.nly Do 1101 sell or distribute

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INDUSTRIAL TRUCK DIVISION

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SAFETY INSTRUCTIONS FOR NAINTAINING INDUSTRIAL TRUCKS Powered industrial trucks may become hazardous if adequate maintenance is neglected. fore, adequate maintenance facilities, personnel and procedures should be provided.

There­

Maintenance and inspection of all powered industrial trucks should be performed in confor­ mance with the recommendation in this manual and the following practices.

1.

A scheduled preventive maintenance, lubrication, and inspection system should be followed.

2.

Only qualified and authorized personnel should be permitted to maintain, repair, adjust, and inspect industrial trucks.

J.

Before Leaving The Truck:

4.

A.

Stop truck.

B.

Fully lower the load engaging means.

C,

Place directional controls in neutral.

D.

Apply the parking brake.

E.

Stop the engine or turn off power.

F.

Lock the control or ignition circuit.

G.

Block the wheels if truck is on a ramp, or being worked on.

Before Working On Truck: A.

Raise wheels free of floor or disconnect power source.

B.

Use chocks or other positive truck positioning devices.

C.

Block load engaging means, innermast(s), or chassis before 1�orking under them.

Before working on engine fuel system of gasoline powered trucks with gravity feed fuel systems, be sure fuel shutoff valve is closed.

Before working on engine fuel system of LP gas powered trucks, close LP gas cylinder valve and run engine until fuel in system is depleted and engine stops running.

Operation to check performance of the truck or attachments should be conducted in an authorized, safe clearance area.

5.

Before Starting To Operate The Truck: A.

Be in operating position.

B.

Depress clutch (or brake pedal on automatic transmission and electric trucks).

C.

Place directional controls in neutral.

D.

Start engine or turn on power.

E.

Before operating truck, check functioning of I ift and tilt systems, directional and speed controls, steering, warning devices, brakes, and any attachment. (If used)

F.

Release parking brake.

- continued Copyrighted Material

T4�a.S,rCLI\PvdOO,"fll<6i3' (FRONT) Do not sell or distribute

INDUSTRIAL TRUCK DIVISION SAFETY INSTRUCTIONS FOR MAINTAINING INDUSTRIAL TRUCKS 6.

Avoid fire hazards and have fire protection equipment present. Do not use an open flame to check level, or for leakage, of fuel, electrolyte or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts.

7.

Properly ventilate work area, vent exhaust fumes and keep shop clean and floor dry.

8.

Handle LP gas cylinders with care.

9.

Brakes, steering mechanisms, control mechanisms, warning devices, I ights, governors, I ift overload devices, guards and safety devices should be inspected regularly and maintained in a safe operating condition.

Do not drop, dent, or damage in any way.

10. All parts of 1 ift and tilt mechanisms and frame members should be carefully and regularly inspected and maintained in a safe operating condition.

11. Special trucks or devices designed and approved for hazardous area operation should receive special attention to ensure that maintenance preserves the original, approved safe operating features.

12. Fuel systems should be checked for leaks and condition of parts. Extra special consideration should be given in the case of a leak in the fuel system. Action should be taken to prevent the use of the truck until the leak has been corrected.

13. All hydraulic systems should be regularly inspected and maintained in conformance with good practice. Tilt cylinders, valves, and other similar parts should be checked to assure that "drift" has not developed to the extent that it would create a hazard.

14. Capacity, operation and maintenance instructions plates, tags, or decals should be maintained in legible condition.

15. Batteries, motors, controllers, 1 imit switches, protective devices, electrical conductors and connections should be inspected and maintained in conformance with good practice. Special attention should be paid to the condition of electrical insulation.

16. Industrial trucks should be kept in a clean condition to minimize fire hazards and facilitate detection of loose or defective parts.

17. Modifications and additions which affect capacity and safe truck operation should not be performed by the customer or user without manufacturers prior written approval.

Capacity, operation and maintenance Instruction plates, tags or decals should be changed accordingly.

18. Care should be taken to assure that all replacement parts are interchangeable with the original parts and of a quality equal to that provided in the original equipment.

Copyrighted Material

1 0 2 3-Z Intdil&.I foo::L� d�Mi K�y Do not sell or distribute

CLARK EQUIPMENT COMPANY, SERVICE DIVISION

INDEX

8

INDEX Lube Chart........ .... . "........................ ................ 12 Operadon............................................ ........ 10, 11 Service Check Sheets................................ 13, 14 Specificadons.. .... ............................................. ". 9

Specifications.............. .......... ................ ·-···.. V - 6 Starciag �totor.............. ................ .... .............. V - 3 Trouble Shooting Guide............................ V - 5,6 Voltage Regulacor.. .................. ...... . -......... V - 4,5

SECTI ON I -BRAKE SYSTEM

SECTION VI· ENG INE Camshaft......................... ....... , ............ ........ VI • 5,6 Compression."........... .................................... VI• 1 Connecting Rods._.............................. .......... Vi • 4 Connecting RodsBearings...................... VI• 3,4 Crankshaft .. . ". ...... ........ -... ...... ................ ...... VI • 6 Cylinder Head........._. ........................ ......... VI - 1 Flywheel.. ................ ........... ". .................... VI· 6,7 Governor........ ...... .... ...... .... ....."............. .... . VI - 7,8 Main .Bearings........ ...... ............ .......... .......... VI • 3 · Oil Pres · sure...._._. .......................................... VI - 7 Piston, Rings lad P�na .... ...... ... ". ............ VI• 4�5 Specifications••. ". .. ............................... _. VI • 9,10 Trouble Shooting Guide... ...............; ........ VI• 8,9 Valves ...................... .............................. VI - 1,2,3

Bleeding Brakes............ ............................ .... 1 • 1 Brake Adjustment.. ............ .................. .......... I - ·3 Brake Pedal Adjustment........ .... .......... ........ I • 2 Brake Shoes........................ ..... ". ...... ........ ...... I• 3 Hand Brake...... ....•.......•......................... ........ I • 3 Hydrovac... �. .................. ...... ... "................... I - 3,4 Master Cylinder ...................... .......... .... .......... I - 1 Wheel Cylinder .............. ........ ....................... , I - 2 SECTION II• TORQUE CONVERTER Descripdon............................. ...................... II • 1 Operation.... .......................................... .... II - 2,3,4 Overhaul.. ................. ............................ 11 - 4,S,6,7 Reassembly......................................... .......... II • 7

SECTION vn. FUEL SYSTEM Carburetor ...................... ................... _. .. VII• 1,2,3 Fuel Pump................................................... VD· 1 Fuel Tank.................................................. VU - 1 Metering Valve.................... ................ ........ VD - 3 Trouble Shooting Guide .......................... Vll• 3,4

Trouble Shooting Guide...... ....... .... .... .. II• 8,9,10 SECTION Ill• COOLING SYSTEM De scripdon....................... .......................... III • 1 Fan Assembly............ .......... ,.................... .. 111 - l_ Thennoscac.... ........ ........ ·····-· ...... ................ 111 • 1 Water Pump............ ................ ............... """· III• 2

SECTION Vlll - HYDRAUL IC SYSTEM Flow Concrol Valve......................... ........ Vlll • 6 Hydraulic Oil.. ....:..... .......... ................ ........ VDI• 1 Leakage Tests.... .................. .................... VDI • 4 Pump, Main..................................... -. ...... VID - 1,i Steering Booster Pump.... .......................... Vlll• 2 Tilt Cylinder.. ................. . ;.. :................. Vlll • S,6 Tilt Lode Valve.................... .................. VIII• 4,5 U pright.................. ...................................... VDI • 6 Valve, Maia...... .............................. ...... VOi • 2,3,4

SECTION IV DRIVE AXLE AND DIFFERENTIAL Backlash Adjusunent.. .. .. ;...... ;........ .... ...... ..

Cleaning and Inspection........ ....................

Differential and Carrier.. ............................

Disassembly.. ...... .............................. .... ......

IV• 5 IV• 3 IV• 2 IV - 1 Malntenaoce ·-··· ..•······· ··.. ·····.. ········-······--· .. IV • 1 Pinion.............................. ............................ IV • 2 Planet Spider...... .... ................................. -. IV • 3 Reassembly.. ........ .... ........ .... .......... .......... .... IV• 4 Trouble Shooting Guide.. ............................ IV - 6

SECTION IX• STEERING SYSTEM . Azle.. .............................. ............................ ........ IX-1 Booster Cylinder.............. .......... ............ IX • 3,4,5 ·steering Gear ... -. .............. .............". ........ IX • 2,·3 SECTION X• TRANSM ISSION

SECTION V - EL ECTRICAL SYSTEM

Description................ ............ ........................ X • 1 Disassembly.......... .............................. X - 4,5,6,7

Baccery .......................................... ...... ...... .... V · 1

Dlstribucor ·"· .............. ·"·.... .... .... .... .. ........ V - 1, 2 Geoeracor ............................................. ...... V• 2, 3 Ignition Coil...... ,............... .............. ...... ...... •· V• 4 Solenoid........ ........ ........................................ V • 3 Spark Plugs.................................................. V • 4

Lubricacion .. ............ ............ ........................ X - 11

as

Operation....... -. .... ................................ ...... .... X -11 Overhaul .. . ............. ...... ·-· ........ .............. .... .... X • 4 Reassembly.. ....... .... ......... .................... X - 8,9, 10

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

CLARK EQUIPMENT COMPANY, SERVICE DIVISION

SPECIFICATIONS 9

SPECIFICATIONS -

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80 PREAD

sa.!.

INSIDE TREAD

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OUTSIDE TREAD

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TURN RADIUS

TIRES PNEUMATIC CY•150

STO. OPT ,

C Y-t BOS

C Y•16S

9:00 X 20

9:00 X 20

10:00 X 20

10:0o X 20

----

10:00 X 20

t

F O.A. HEIGHT RAUEO

E

UPRIGHT HEIGHT RAISED

D

O.A. HEIGHT LOWERED

2.!.

2

28-••.,.�----------112 ------------- 2 9 ----- 48

-------------189----------------, Coolin� System

Tor1.1uc Converter line.I Transmjssion

211}

29 r,al.

(,

'}••·

2') r, �•-

22 \}Is.

16 QIS.

1n

259

2R}

29 (;al.

(,

Qu.

29 t;al.

22 Q••·

157', 2,'l', 2Rl', 19 Gal.

(,

Qu.

2'> <i-41.

22 f}IS.

'l

C

I)

CY-110

77

6t. ! l

59

<:\-165

77

(;f>�-; 59

�9�4

Fuel Tank

15 ?

-�

CY-I ROS 77�4 67�4

Suonp Tank

E HI!

\toJcl

F

Crankcase

88 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

4510-M-88-57 Drive, Axle

� Diff.

Wheel EnJs

14 Pt.

8 P,. F.ach

If- Qu.

14 P1.

8 P,. Each

16 (./ts.

14 "'·

8 P1. E11ch

10

CLARK EQUIPMENT COMPANY, SERVICE DIVISION

OPFRATION

OPERATING INSTRUCTIONS are a few preventive maintenance instru ctions that should be followed: 1. Check fuel supply and fuel system lines and connections.

2. Check cooling system; refill with water or anti-freeze.

3. Check crankcase oil level.

4. Check service brake and hand brake.

5. Check air cleaner.

6. Check hydraulic system.

7. Check transmission oil level.

It is not essential that the prospective opera­ tor have experience with this type machine, it is important that he have sound practical knowledge of machinery and its care. An opera­ tor with previous experience on automotive equipment should readily become acquainted with construction and operation of the lift truck.

The mac hine has been throughly tested at the factory before shipment and in the hands of a competent operator will give highly satisfac­ tory results.

STARTING

BEFORE STARTING

Take p osition in drivers seat.

Place d irectional control lever in "neutral". The machine is equipped with a neutral starting

Before p utdns machine into service there

SPEED C ONTROL LEVER

IGNITION ANO STARTER SWITCH HOBBS HOUR METER HANO BRAKE

RANGE SELECTOR TRANSMISSION TEMPERATURE INDICATuR LIGHT

CHOKE

TRANSMISSION PRESSURE INDICATOR LIGHT

Figure 1. Operating Controls 2-25-IS 7

88

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ACCELERATOR

4509 - M-88-56